California Department of Transportation

The New California WideFlange Girder

A Super Girder for California Bridges
Presented by: Michael Pope, P.E. Jay Holombo, Pd.D., P.E.
September 22rd, 2009 Sacramento Convention Center Sacramento, California

California Department of Transportation

Contract for Performance and Innovation

Deputy directors commitment for innovation

Establish a candidate list of projects to be considered for a pilot program to demonstrate accelerated bridge construction (ABC) practices.

California Department of Transportation

Recent ABC Projects in California

MacArthur Maze Reconstruction - Oakland Geyserville Oakland

I-5 Truck Route Fire Repair - San Fernando

San Fernando Mojave Russian River Bridge Replace - Geyserville SR 40 Mojave Bridges - Needles/Barstow

California Department of Transportation

California Cast-in-Place Box Girder

Advantages Seismically Resilient Shallow Superstructure / Aesthetics Cost Drawbacks Construction Time Urban Issues / Vertical Clearance Driver Inconvenience / Safety

California Department of Transportation

California Cast-in-Place P/T Box Girder

Folsom Bridge Over Lake Natoma

Folsom

California Department of Transportation

California Pre-tensioned I-Girder

Facts About The California I-Girder Used in California Since the 1960s Common Span Lengths 50 100 ft. Great for Widening Existing Bridges Good Deflection Control Deck Removal / Replacement Reduced Construction Time

California Department of Transportation

California Pre-tensioned I-Girder

California Department of Transportation

California Bulb-Tee Girder

Girder Characteristics:

Used to Span Between Bents, or Spliced to Achieve Longer Spans Simple Pre-tensioned Multi-Span Cont. for LL Spliced Multi-Span P-T

D/S = 0.050 D/S = 0.045 D/S = 0.042

Spans 150+ feet Un-spliced Hauling Length Limitations Span Lengths up to 200+ feet When Segments are spliced Together with PostTensioning

California Department of Transportation

Genesis of Spliced Girder Design

Spliced Girder Research

NCHRP 12-57 Extending Span Ranges of Precast, Prestressed Concrete Girders Ralph Whitehead & Associates LRFD Article 5.14.1.3 - Spliced Precast Girders Three Comprehensive Design Examples

California Department of Transportation

LRFD Introduces Spliced Girders

AASHTO LRFD Code

Defines Spliced Girders as a Unique Structure Type in 2005 Interims 4 Pages of Code & Commentary Devoted to Spliced Girders Three Comprehensive Design Examples

California Department of Transportation

NCHRP Report 517 Design Examples

Design Example 1
200 foot Single Span Spliced PCI BT Girder 14 inch Wet Splice on Temporary Towers 96 in. Deep Modified PCI Bulb-tees with an 8 in. Web 3 Girder Segments Center Segment = 90 feet Depth-to-Span Ratio = 0.044

California Department of Transportation

NCHRP Report 517 Design Examples

Design Example 2
Two-Span Spliced U Beam Girder Precast Alternative for Typical California CIP Box Girder Overcrossing 6 Foot Deep U-Beams (California Bathtub) Spans Designed with both 2 and 3 Girder Segments Depth-to-Span Ratio = 0.041

California Department of Transportation

NCHRP Report 517 Design Examples

Design Example 3
Continuous Three Span Haunched Spliced Girder Concept Developed for Water Crossings in Florida 280 foot Main Span, with Equal 210 foot End Spans Midspan Girder Depth = 7-6 (overall D/S = 0.030) Haunched Girder Depth = 15-0 (overall D/S = 0.057)

California Department of Transportation

Seismic Performance

California Department of Transportation

Seismic Testing - UCSD

UCSD Seismic Testing
Girder and Bent Cap Details in the Integral Column to Cap connection Region:

Fully reversed horizontal Displacement cycles until target ductilities have been reached. Return specimen to undisplaced position, disengage horizontal actuators for subsequent vertical displacement cycles to failure.

California Department of Transportation

Seismic Testing - UCSD

Applied Seismic Loading

Column Subjected to Incremental Displacement Cycles, up to a ductility = 8 With a Column Diameter to Structure of about 1, a Large Plastic Moment delivered to the Bent Cap.

San Diego

California Department of Transportation

Seismic Testing - UCSD

Superstructure Performance

Bent Cap Withstands Plastic Moment Induced by Column Girders Remain Essentially Elastic with Small Cracks

Bent Cap Torsional Mechanism - Forces to Exterior Girders Post-Tensioned Bent Cap Clamps Girders Together - Increases Torsional Rigidity

California Department of Transportation

California Pre-tensioned Bulb-Tee Girder

San Mateo Hayward Bridge Widen

2169 ea 90 foot Bulb-Tee Girders

Hayward

California Department of Transportation

California Pre-tensioned Bulb-Tee Girder

Main Street Bridge Cottonwood Creek

Cottonwood Lathrop

California Department of Transportation

California Post-tensioned Bulb-Tee Girder

Sacramento River Bridge Interstate 5

Anderson

California Department of Transportation

California Post-tensioned Bulb-Tee Girder

Fiberboard Undercrossing Interstate 80

Truckee

California Department of Transportation

California Post-tensioned Bulb-Tee Girder

Jefferson Boulevard Canal Bridge

West Sacramento

California Department of Transportation

California Post-tensioned Bulb-Tee Girder

Angeles Crest Bridge State Route 39

Wrightwood

California Department of Transportation

California Wide-Flange Girder

Why Is California Interested in this New Shape?

California Department of Transportation

California Wide-Flange Girder

LRFD Code Requirements
HL93 Live Load Case for Service III
Design California P-15 Permit Vehicle for Strength II Design (versus the P-13)

7 Pairs of Axles vs. 6 Pairs Increase from 48 to 54 kips / Pair

Permit Truck Load Factor Increase Dynamic Load Allowance (IM) = 1.33 Live Load Distribution Factors

California Department of Transportation

California Wide-Flange Girder

Comparison With Existing California Bulb-Tee

Wider Bottom Flange (3-8 and 3-9 ) Greater Capacity for Pretensioned Strand (38% Increase) Thinner Web (6 and 7 ) Thinner Top Flange

66 Strands

48 Strands

California Department of Transportation

California Wide-Flange Girder

Additional Benefits of the New Shape

A Wider Bottom Flange Results in:

Increased Eccentricity with Lower Strand Pattern Enhanced Lateral Stability During Transportation Decrease in Initial Concrete Strength, fci Decrease in Final Concrete Strength, fc, at Bent Cap

Thinner Top Flange Reduces Weight Web: 6 in. Pretensioned and 7 in. Post-tensioned LRFD Shear Requirements Satisfied With Thinner Web

California Department of Transportation

The New California WideFlange Girder

A Super Girder for California Bridges

Thank You!!!
Introducing: Jay Holombo, Ph.D., P.E.
September 22rd, 2009 Sacramento Convention Center Sacramento, California

Comparative Design Example CAWF versus Cast-in-Place

Western Bridge Engineers Seminar
September 22, 2009

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California Bridge Market

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California Bridge Market

Caltrans administered (2003 2007) Precast Concrete $167M / year Cast-in-place: $153 / sq. ft Precast: Steel: $257 / sq. ft $481 / sq. ft Cast-in-place: 85% 14%

Steel

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Comparative design study CAWF vs. cast-in-place

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Super Girder

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Super Girder

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Threaded Rod Continuity

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Threaded Rod Continuity Internal

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Threaded Rod Continuity - External

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Threaded Rod Validation Testing

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Bent Cap

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Bent Cap

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UCSD

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Abutments

CIP Box Girder Alternative

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Threaded Rod Alternative

Comparison by Component
Item Superstructure Substructure Other* Total Super G $2,034,000 $770,000 $398,000 $3,202,000 CIP Box $2,515,000 $1,055,000 $304,000 $3,874,000 CIP/Super G 1.24 1.37 0.76 1.21

Item Superstructure Substructure Other* Total

Super G 1.2 months 2.2 months 0.4 months 3.8 months

CIP Box 2.4 months 2.2 months 0.4 months 5.0 months

CIP/Super G 2.0 1.0 1.0 1.3

*Includes approach slab, concrete barriers and joint seal 47

Acknowledgements

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